PARTICLE

BOARD AND
HINGES
❑ PARTICLE BOARD MADE BY COMPRESSING SMALL PARTICLE OF WOOD ( SAW DUST AND SMALL PARTICLE OF WOOD ).

❑ WOOD PARTICLES ARE MIXED WITH GLUE

❑ MIXTURE IS FIRMLY PRESSED TOGETHER USING HOT PRESS MACHINE .

❑ PARTICLE BOARD IS A COMPOSITE MATERIAL

❑ FIRST MADE IN GERMANY IN 1940

USES

USED TO MAKE READY MADE FURNITURE , KITCHEN CABINETS ,FALSE CEILING , WALL PANELS AND PARTITIONS.

PROPERTIES
AGE USUALLY NOT MORE THAN 5 YEARS .
VERY SENSITIVE TO MOISTURE AND AND WATER.
VERY LIGHT WEIGHT .
ECO FRIENDLY AS IT IS MADE UP OF WASTE
WOOD PARTICLES .
CHARACTERISTICS OF PARTICLE BOARD

❑ CHEAPER ,

❑ DENSER AND MORE UNIFORM THAN CONVENTIONAL WOOD AND PLYWOOD

❑ IS SUBSTITUTED FOR THEM WHEN APPEARANCE AND STRENGTH ARE LESS IMPORTANT THAN COST .

❑ PARTICLE BOARD CAN BE MADE MORE ATTRACTIVE BY PAINTING OR USE OF WOOD VENEERS THAT ARE GLUED
ON TO SURFACE THAT WILL BE VISIBLE .

❑ THE STRENGTH OF THE BOARD WILL DEPEND ON-

• DENSITY
• THICKNESS
• LAYERED
• GRADED STRUCTURES
• ADHESIVE
ADVANTAGES

❑ CHEAPER THAN SOLID TIMBER.

❑ AVAILABLE IN LARGE FLAT SHEETS
❑ SOLID TIMBER IS PRONE TO WRAPPING AND SPLITTING WITH CHANGES IN HUMIDITY
❑ WHERE AS PARTICLE BOARD DO NOT .
❑ USE OF TIMBER VINEERS ON PARTICLE BOARD HAS DECREASED THE DEMAND FOR NATIVE HARDWOOD TIMBERS IN
FURNITURE CONSTRUCTION .

DISADVANTAGES

❑ IT IS RARELY USED OUTDOOR OR PLACES THAT HAVE HIGH LEVEL OF MOISTURE WITH THE EXCEPTION OF SOME
BATHROOMS , KITCHENS , AND LAUNDRIES WHERE IT IS COMMONLY USED AS AN UNDERLAYMENT BENEATH A
CONTINUOUS SHEET OF VENYL FLOORING .
❑ CUTTING ARE NOT POSSIBLE ON PARTICLE BOARD
❑ DESIGN CAN NOT BE MADE ON PARTICLE BOARD

PARTICLE BOARD SIZE – 8*4

THICKNESS 8-30 MM
PRICE – 30/- SQFT - 90RS/-SQFT
MANUFACTURERS IN INDIA

JADHAMBHA PARTICLE BOARD -5-10MM

AHMEDABAD - 26/- SQFT

LEO CLASSICAL PLAIN PARTICLE BOARD - 8- 25MM

HYDERBAD - 20/- SHEET

SMART WOOD WHITE CEMENT BONDED PARTICLE BOARD 6MM-12MM

CHENNAI - 25/-SQFT

ASSOCIATE GREY AND IVORY PARTICLE BOARD - 8MM

CHENNAI - 28/-SQFT
MANUFACTURING PROCESS

1. RAW MATERIAL PREPARATION

DEBARKING UNDERTAKEN TO REMOVE BARK WHICH CAN REDUCE THE PROPERTIES OF PARTICLEBOARD IF PRESENT IN
QUANTITIES MORE THAN A FEW PER CENT
– ROTARY DEBARKER
– DRUM DEBARKER
SORTING CLASSIFICATION OF WASTE WOOD
REMOVAL OF METALLIC AND OTHER CONTAMINANTS

2. CONVERSION OF PARTICLES
• AIM TO MANUFACTURE A HOMOGENEOUS PRODUCT
•NEED THEREFORE TO PRODUCE CHIPS OF A SUITABLE SIZE &
SHAPE TO FORM THE FURNISH FOR THE BOARD

CHIPPING
REDUCTION MAY THEREFORE BE A TWO STAGE PROCESS. FOR
EXAMPLE, PRIMARY REDUCTION OF DEBARKED LOGS TO GIVE
LARGE, COARSE CHIPS, FOLLOWED BY FURTHER MILLING TO
PRODUCE MORE “ENGINEERED” CHIPS
TYPES OF EQUIPMENT

KNIFE SYSTEMS
– USE KNIVES CUT OR SLICE CHIPS FROM THE RAW MATERIAL
– DISC/DRUM CHIPPERS
• HAMMER MILL SYSTEMS
– USE HAMMERS TO GRIND, BREAK, TEAR SHRED RAW MATERIALS INTO SMALLER PARTICLES
• ATTRITION SYSTEMS
– GRIND THE WOOD RAW MATERIAL INTO FIBRE – SIMILAR TO TMP (THERMOMECHANICAL PULP)

3. PARTICLE DRYING

Why?
•HIGH MC OF CHIPS FROM GREEN WOOD TOO HIGH (>100%) FOR PRESSING – CAN LEAD TO THE DEVELOPMENT OF HIGH
VAPOUR PRESSURE IN BOARDS LEADING TO DELAMINATION OR “BLOWS”.
• DRIERS WORK ON THE PRINCIPLE OF PASSING THE PARTICLES THROUGH A STREAM OF HOT AIR (180-200OC)
• VARIOUS TYPES OF DRYER E.G.
• • DRUM TYPE (ROTARY/FIXED)
• • BELT DRYERS
• • PADDLE TROUGH DRYERS
• • SUSPENSION-TYPE
• • “FLASH” DRIERS (HIGH TEMPERATURE)
 4. PARTICLE CLASSIFICATION
WHY?
•CONTROL PARTICLE SIZE DISTRIBUTION – IMPORTANT SO AS TO OPTIMISE THE POSITION AND SIZE OF THE PARTICLES
RELATIVE TO THEIR POSITION IN THE BOARD – SMALL PARTICLES ON THE SURFACE, BIGGER PARTICLES IN THE CORE
•NEED TO ENSURE THAT THE BOARD IS “BALANCED”, I.E. THE SAME AMOUNT OF SURFACE PARTICLES ON BOTH FACES
OF THE BOARD (C.F. PLYWOOD). OTHERWISE MAY RESULT IN DISTORTION OF THE BOARD
• NOTE: VERY SMALL PARTICLES (FINES) WILL CONSUME MORE RESIN (HIGH SURFACE AREA TO WEIGHT RATIO)
•SIEVING – PASS PARTICLE THROUGH DIFFERENT SIZED SIEVES, LARGER PARTICLES ARE RETAINED, SMALLER PARTICLES
PASS THROUGH TO THE NEXT SIZE DOWN
• AIR CLASSIFICATION – SUSPENDED IN AN AIR STREAM; THE SMALLER, LIGHTER, PARTICLES ARE CARRIED AWAY IN THE
AIR STREAM, LEAVING THE LARGER HEAVIER PARTICLES (LOWER SURFACE AREA TO WEIGHT RATIO)

5. GLUING AND BLENDING

• AN ADHESIVE OR GLUE NEEDS TO BE APPLIED TO THE SURFACE OF THE PARTICLES TO BIND THE PARTICLES TOGETHER
• DIFFERENT RESINS HAVE DIFFERENT PERFORMANCE CHARACTERISTICS:
– UF; BRITTLE AND SUBJECT TO HYDROLYSIS
– MUF; BETTER MOISTURE RESISTANCE THAN STANDARD UF
– PF; MORE RESILIENT AND LESS SUBJECT TO HYDROLYSIS
– MDI; HIGHLY REACTIVE AND BONDS WELL
• THE RESINS ARE GENERALLY APPLIED AS LIQUIDS IN THE FORM OF AN ATOMISED SPRAY
–NOTE: CAN ALSO BE APPLIED IN SOLID (POWDER) FROM THAT, FORMS A LIQUID ON HEATING, BEFORE
REVERTING TO AN INSOLUBLE, INFUSIBLE, SOLID FORM (E.G. PF)
6. FORMING
• LAYING UP THE “FURNISH” PRIOR TO PRE-PRESSING AND HOT PRESSING (CONSOLIDATION)
•IMPORTANT PROCESS IN THE FORMATION OF THE STRUCTURE OF THE BOARD AND THEREFORE STRONGLY AFFECTS THE
BOARD PROPERTIES:
– IMPROVED BENDING PROPERTIES
– GOOD SURFACE FINISH
– OPTIMISED DENSITY
•BOARDS MAY BE “SINGLE LAYER”,
“MULTI-LAYER” (3,5), OR “GRADUATED”

• MUST ALWAYS BE A “BALANCED”

STRUCTURE TO PREVENT DISTORTION OR POOR
PROPERTIES (I.E. 2 OR 4 LAYER NO GOOD)

•SURFACE LAYERS OF “FINE” PARTICLES,

“CORE” OF COARSER PARTICLES

•MC OF SURFACE LAYERS 8-15%;

CORE 4-8%

• RESIN CONTENT OF SURFACE

LAYERS
MAY ALSO BE HIGHER TO GIVE
IMPROVED STRENGTH
7. Pre-pressing & hot pressing
• Pre-pressing of the furnish to reduce the bulk and give some mechanical strength to the mattress
• Hot-pressing, to finally consolidate the board and cure the adhesive. Density profile generated during hot-pressing
• Various types of press, the most common being a continuous press.

PRE-PRESSING
• PART OF THE CONSOLIDATION PROCESS
• PRE-PRESSING UNDERTAKEN TO:
– REDUCE THE THICKNESS OF THE MATTRESS (I.E. INCREASE THE BULK DENSITY OF THE
MATTRESS
– GIVE THE MATTRESS SOME MECHANICAL STRENGTH FOR HANDLING
– SPEED UP THE HOT PRESS PROCESS, REDUCE PRE-CURE
What is going on in the pressing process?
• Heat transfer and flow of gasses
• Phase change of water
• Densification of material
• Adhesive cure
• Development of internal stresses

HOT-PRESSING
• MAIN MECHANISM FOR CONSOLIDATION OF THE MATTRESS,
THE DEVELOPMENT OF THE BOARD INTERNAL STRUCTURE (IN
COMBINATION WITH FORMING ETC…) AND CURING THE
ADHESIVE BINDING THE PARTICLES TOGETHER
• PRESSING MAY BE BATCH-WISE IN A SINGLE OR MULTI OPENING
PRESS, OR IN A CONTINUOUS PRESS (“CONTIPRESS”)
8. COOLING AND FINISHING

• AT EXIT FROM PRESS, ADHESIVE CURED SUFFICIENTLY TO RETAIN BOARD INTEGRITY

•SOME FURTHER “CURING” MAY TAKE PLACE (USED TO BE COMMON TO “HOT STACK” FINISHED PANELS TO CURE THE RESIN
FURTHER)
•PANELS NEED TO BE COOLED BEFORE FINISHING (E.G. SANDING) AS IF DONE TOO SOON, BOARD PROPERTIES MAY BE
AFFECTED AND TOOLS WILL BECOME CLOGGED
• ON EXIT BOARDS TRIMMED BEFORE COOLING
 Hinges
MOVABLE JOINTS USED TO ATTACH,
SUPPORT, AND TURN A DOOR (OR COVER)
ABOUT A PIVOT; CONSIST OF TWO PLATES
JOINED TOGETHER BY A PIN WHICH SUPPORT
THE DOOR AND CONNECT IT TO ITS
FRAME, ENABLING IT TO SWING OPEN OR
CLOSED.
• Hinges generally consist of two
leaves & a knuckle.
• The knuckle is formed by
interlocking parts usually an odd
number.
• A pin runs through the centre of the
knuckle, this acts as an axis
• Hinges are made from brass or steel
•
• Butt Hinge:
From application ranging from doors, windows, cabinets and almost all furniture these are the most
commonly used type of hinges.
Hinges for use in the interior doors are made of steel mostly, while when used for exterior doors one
needs to
take care of the risk of corrosion, so brass or stainless steel hinge are more appropriate for Interior
design projects.
• Butt Hinges are generally 6 inches in length or shorter.
• Butt Hinges are most commonly used on doors, fabricated panels, etc.
• It is a hinge with two rectangular metal plates with screw holes joined by
either a pin or rod.
• Butt Hinges are most commonly used in multiples, three or fours. Butt Hinges for
exterior doors are often made of brass, stainless steel, or aluminum to prevent
corrosion.
Pivot Hinges:

These hinges are designed for overlay doors, where one part is mounted on top and the other on the bottom of the
door, resulting in a concealed hinge. These are available for both light weight and heavy duty usages.

The key advantage is that this hinge doesn’t block the door to be opened in both directions
and being mounted at the far ends, they allow a seamless view.

Barrel Hinge:

It consists of components like a barrel which is a hollow spherical barrel shaped section joined to a
pivot for movement. So, basically a barrel hinge consists of two parts.

This typology of hinge is simpler to fix and can be dismantled when required. Materials from which
hinges are made include: coated steel, polished plated steel, chromium-plated metals, brass, bronze,
and aluminium. Placement and number required varies according to door material and size
 Piano Hinge

• This type of hinge is also known as a continuous hinge. It runs the entire length of the door. Piano hinges are
manufactured with or without holes. These hinges also come in various thicknesses, pin diameters, and
knuckle lengths.
• run across the entire length of the piano’s flat edge.
• to cover the length of an entire two objects that needs to be joined together. It’s application ranges
from toolbox, folding wall partitions, shower doors apart from the obvious piano construction.

Gate Hinge
• These hinges are ideal for either light and heavy duty places or gates.
• are available in stainless steel, brass, bronze and other high-tech materials.
• In this an L-shaped screw is fitted into the post which is attached to the gate.
• They are also available as self-closing types.